Flume apparatus and method for modular heat exchange tower

ABSTRACT

The present disclosure relates to a modular heat exchange tower including a first module having a first basin disposed therein and a second module having a second basin disposed therein. The aforementioned modular heat exchange tower may also include heat exchange sections, which are disposed in the first module and the second module. The first module and the second module may be assembled prior to being transported to a job site and installed in the modular heat exchange tower.

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.62/341,876, titled Improved Flume Apparatus and Method for Modular HeatExchange Tower, filed May 26, 2016, the disclosures of each which arehereby incorporated by reference in their entirety.

FIELD OF THE INVENTION

The present disclosure relates generally to modular heat exchangetowers. The present disclosure also relates to methods of assemblingmodular heat exchange towers. More particularly, the present disclosurerelates, for example, to modular components of heat exchange towers,each having separate water basins disposed therein, that can bepre-assembled in a factory setting and transported to a job site andassembled to erect a cooling tower.

BACKGROUND OF THE INVENTION

Cooling towers are heat exchangers of a type widely used to emanate lowgrade heat into the atmosphere and are typically utilized in electricitygeneration, air conditioning installations, and the like. These towersreceive a relatively warm or hot fluid, and pass the fluid through thetower apparatus so that heat is extracted from the fluid by interactionwith relatively cooler ambient air.

Cooling towers generally include counter-flow type cooling towers andcross-flow type cooling towers. In a counter-flow cooling tower, liquidof high temperature is cooled as it flows downwards through fill orpacking and is brought into contact with air traveling upwards.Conversely, in a cross-flow cooling tower, liquid of high temperature iscooled with air that moves horizontally through the fill or packing. Theheated air is exhausted into the atmosphere using a fan, and the coolingliquid is collected in a basin situated below the fill or packing.

Liquid is generally distributed through a cooling tower in one of twoways: gravity and spray. Typically, gravity systems are used incross-flow cooling towers, and spray systems are used in counter-flowcooling towers. In a spray system, liquid of high temperature isdistributed through the cooling tower using a series of spray nozzlesmounted on distribution pipes. The spray nozzles are arranged to evenlydistribute the liquid over the top of the fill. Once the liquid travelsthrough the fill, it is collected at the bottom of the tower in a coldliquid basin. In a gravity system, liquid of high temperature is fedinto a hot liquid basin disposed above the fill. The liquid then travelsthrough holes or openings in the bottom of the hot liquid basin to thefill. Similar to the spray system, liquid that travels through the fillis collected at the bottom of the tower in a cold liquid basin.

A drawback associated with current cooling towers is that in someapplications they can be very labor intensive in their assembly at thejob site. The assembly of such towers oftentimes requires a dedicatedlabor force investing a large amount of hours. Accordingly, suchassembly is labor intensive requiring a large amount of time andtherefore can be costly. Uncertainties such as weather and siteconditions may also affect the time required to assemble cooling towersat a job site. The quality of the labor force may also lead to qualityand performance issues associated with the towers. Thus, it is desirableto assemble as much of the tower structure at the manufacturing plant orfacility, prior to shipping it to the installation site.

But while it may be desirable to assemble tower components at a factory,conventional designs for cooling towers oftentimes necessitate theirassembly at a job site. For example, factors such as the size of thevarious tower components and their structural strength may limit theirability to be manufactured at the factory and transported onsite. Oneparticular component that may present assembly and transportationchallenges is the liquid collection basin or commonly referred to as thecold water basin. Many conventional cooling towers are constructed witha single cold water basin for receiving and holding water that has beencooled by the tower. Due to the size of the cold water basin, it iscostly to transport it in pre-assembled form to a job site. In coolingtowers with a single cold water basin, the size of the cold water basinalso increases as the towers increase in cooling capacity. While asolution may be to ship the cold water basin in multiple components to ajob site for final assembly, such leads to greater labor costs andinconsistent quality in assembly due to on-site conditions such as thosedescribed above. Moreover, it oftentimes is difficult to ensure that thevarious components of the cold water basin are fully sealed to oneanother at a job site.

Therefore, it is desirable to have a cooling tower that is assembledusing components that can be manufactured in a factory and transportedto a job site. In particular, it is desirable to have a cooling towerthat can be assembled with modular components, including components thathave pre-assembled cold water basins.

SUMMARY OF THE INVENTION

Embodiments of the present disclosure advantageously provide for modularheat exchange towers and methods of assembling such modular heatexchange towers.

An embodiment of the disclosure is a modular heat exchange tower,comprising: a first module comprising a first basin disposed therein; asecond module comprising a second basin disposed therein; a plenum; afirst heat exchange section; and an air current generator.

Another embodiment is a modular heat exchange tower, comprising: a firstcollection basin module, wherein the first collection basin modulecomprises a first heat exchange portion and a first collection basin; asecond collection basin module, wherein the second collection basinmodule comprises a second heat exchange portion and a second collectionbasin; a plenum module disposed between said first and second collectionbasin modules; and a fan module.

Another embodiment is a method of assembling a modular heat exchangetower, comprising: positioning a first collection basin module, whereinthe first collection basin module comprises a first heat exchangeportion and a first collection basin; positioning a second collectionbasin module laterally spaced apart from the first collection basinmodule, wherein the second collection basin module comprises a secondheat exchange portion and a second collection basin; positioning aplenum module in the lateral space between the first collection basinmodule and the second collection basin module; and positioning a fanmodule vertically adjacent to the plenum module.

In yet another embodiment of the present invention, a modular heatexchange tower that extends vertically along a longitudinal axis,comprising: a first module comprising a first basin disposed therein; asecond module that defines a plenum, wherein said second modulecomprises a outlet; a first flume connected to said outlet, wherein saidflume extends from said second module to said first module, wherein saidfirst flume comprises: a first linear base wall; a first linear sidewall that extends from said linear base wall at an angle; and a secondlinear side wall that opposes said first linear side wall that extendsat an angle from said base wall; a first heat exchange section; and anair current generator.

In still yet another embodiment of the present invention, a modular heatexchange tower that extends vertically along a longitudinal axis,comprising: a first module comprising a first basin disposed therein; asecond module comprising a second basin disposed therein; a third modulethat defines a plenum, wherein said third module comprises a outlet; afirst flume connected to said outlet, wherein said flume extends fromsaid third module to said first module and has a curvilinear geometry; afirst heat exchange section; and an air current generator.

There has thus been outlined, rather broadly, certain embodiments of theinvention in order that the detailed description thereof herein may bebetter understood, and in order that the present contribution to the artmay be better appreciated. There are, of course, additional embodimentsof the invention that will be described below and which will form thesubject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of theinvention in detail, it is to be understood that the invention is notlimited in its application to the details of construction and to thearrangements of the components set forth in the following description orillustrated in the drawings. The invention is capable of embodiments inaddition to those described and of being practiced and carried out invarious ways. Also, it is to be understood that the phraseology andterminology employed herein, as well as the abstract, are for thepurpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conceptionupon which this disclosure is based may readily be utilized as a basisfor the designing of other structures, methods and systems for carryingout the several purposes of the present invention. It is important,therefore, that the claims be regarded as including such equivalentconstructions insofar as they do not depart from the spirit and scope ofthe present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of thisdisclosure, and the manner of attaining them, will become more apparentand the disclosure itself will be better understood by reference to thefollowing description of various embodiments of the disclosure taken inconjunction with the accompanying figures.

FIG. 1 is a perspective view of a first exemplary modular heat exchangetower in accordance with an embodiment of the present disclosure.

FIG. 2 is an exploded view of the modular heat exchange tower depictedin FIG. 1 showing a plurality of modular components of the modular heatexchange tower in accordance with an embodiment of the presentdisclosure.

FIG. 3 is a top view of the modular heat exchange tower depicted in FIG.1 showing an air current generator in accordance with an embodiment ofthe present disclosure.

FIG. 4 is a cross-sectional view of the modular heat exchange towerdepicted in FIG. 1 showing a plurality of heat exchange portions inaccordance with an embodiment of the present disclosure.

FIG. 5 is a perspective view of a second exemplary modular heat exchangetower in accordance with an embodiment of the present disclosure.

FIG. 6 is a top view of the modular heat exchange tower depicted in FIG.5 showing an air current generator in accordance with an embodiment ofthe present disclosure.

FIG. 7 is a cross-sectional view of the modular heat exchange towerdepicted in FIG. 5 showing a plurality of heat exchange portions inaccordance with an embodiment of the present disclosure.

FIG. 8 is an isometric view of a modular heat exchange tower inaccordance with an embodiment of the present invention.

FIG. 9 is a partial cut away view of the modular heat exchange towerdepicted in FIG. 8 illustrating the internal cooling liquid basins.

FIG. 10 is a partial exploded view of the modular heat exchange towerillustrated in FIGS. 8 and 9.

FIG. 11 is another partial exploded view illustrating the cooling liquidbasins in accordance with an embodiment of the present invention.

FIG. 12 is a partial, internal view of the modular heat exchange towerillustrating the liquid flow flume in accordance with an embodiment withthe present invention.

FIG. 13 is an isometric view of a flow path connection of the flume inaccordance with an embodiment of the present invention.

FIG. 14 is a detailed view of the flow path connection depicted in FIG.13.

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description, reference is made to theaccompanying drawings, which form a part hereof and show by way ofillustration specific embodiments in which the invention may bepracticed. These embodiments are described in sufficient detail toenable those skilled in the art to practice them, and it is to beunderstood that other embodiments may be utilized, and that structural,logical, processing, and electrical changes may be made. It should beappreciated that any list of materials or arrangements of elements isfor example purposes only and is by no means intended to be exhaustive.The progression of processing steps described is an example; however,the sequence of steps is not limited to that set forth herein and may bechanged as is known in the art, with the exception of steps necessarilyoccurring in a certain order.

Cooling towers regulate the temperature of relatively warm or hot fluidby passing the fluid through a tower apparatus that brings it intocontact with relatively cooler ambient air. These towers typicallyinclude a hot liquid distribution system. Examples of these distributionsystems may have a series of water distribution nozzles or an apertureddistribution basin or the like, and a cold water collection basinpositioned at the base or bottom of the cooling tower. Commonly, a waterdispersing fill structure is disposed in the space between the hot waterdistribution system and the underlying cold water collection basin. Theaforementioned fill structure oftentimes includes either a plurality ofelongated, horizontally arranged and staggered splash bars supported atspaced intervals by an upright grid structure or frame assembly, or aseries of fill packs or fill packing composed of a number of film fillsheets. During assembly of the evaporative cooling towers, typically, anouter shell or support structure is built first and then the fill mediais installed. In the case of splash type fill, a rack or grid support isaffixed to the support shell. Splash bars are then threaded into therack. The splash bars generally provide a surface for consistent,predictable dispersal and breakup of the water droplets over a range ofwater loadings typically encountered during operation of the evaporativecooling tower. Typically, these splash bars are long and thin and thefill structure includes a great number of them. In the case of filmfill, fill packs may be employed and installed into the supportstructure of the cooling tower. Fill packs may consist of individualsheets glued or attached by some other means to one another to makeblocks. Alternatively, fill packs may consist of sheets hung fromsupport members. Successive sheets are pushed on support members fromone end and push down the support member until the support member ispopulated with the desired number of sheets. The fill packs are thenplaced in the support structure.

In a cross-flow tower, hot liquid is distributed over the fill sectionsuch that it comes into contact with cooler ambient air, which cools thehot liquid as the air travels horizontally or laterally through the fillsection. These towers typically include an air inlet region that isdisposed adjacent to the fill section, which allows air from outside ofthe tower to travel into the fill section. Generally, the dimensions ofthe air inlet region may correspond to the height of the fill section,allowing even distribution of air travel through the fill section. Thetower also includes a plenum area or plenum chamber for receiving theair after it has traveled through the fill section, and a fan or otherair current generator for directing the air into the atmosphere onceagain.

Hot liquid may be distributed in a cooling tower using a pipedistribution system. A pump may feed water into the pipes, which carrythe water to nozzles that eject the water onto the fill section. Theejected water then travels through the fill section and is collected atthe bottom in a cold liquid basin, which may have an opening (e.g., apipe opening) for passing the cold liquid out of the cooling tower. Asan alternative to a pipe distribution system, hot liquid may also bedistributed in a cooling tower using water distribution basins havingapertures for the water to flow through onto the fill section. Such assystem is known as a gravity-driven distribution system. Once the liquidflows through the fill section and is cooled, it is similarly collectedby a cold water basin, which may eject the cooled liquid to the outside.

Systems and methods disclosed herein provide a modular cross-flowcooling tower with a dual water collection basin design. The dual basindesign allows for the separate basins to be pre-assembled in a factoryand transported to a job site for installation into a cooling tower.Each of the basins may have dimensions that allow it to be economicallytransported to a job site. The dual basin design allows the coolingtower to be assembled with basins and other components that are smallerthan a conventional cooling tower without sacrificing cooling capacity.In fact, larger capacities than previous conventional factory assembledcooling towers can be achieved. Furthermore, power conoutlettion perunit of cooling can be reduced with the use of larger fans notpreviously configurable in conventional factory assembled towers. Assuch, such systems and methods provide customers with a high capacitycooling product that is requires less on-site assembly time and laydownspace and reduces transportation costs, installed product costs, safetyconcerns associated with on-site assembly, and downtime.

Conventional cooling towers typically include a single water collectionbasin that is costly to transport due to its size. For example, existingcooling towers may use cold water basins having a width of approximatelyfourteen (14) feet and therefore must be transported with special permitrequirements. Examples of such permit requirements may includerestrictions on the days and times of travel, route restrictions, escortrequirements, lighting requirements, and tolls and other fee payments.These restrictions may differ from location to location, adding to thedifficulty and cost of transportation.

Systems and methods disclosed herein may avoid the transportationproblems associated with existing cooling towers by providing a coolingtower that is assembled with various modular components that do notexceed certain transportation size limits. For example, systems andmethods disclosed herein may provide a cooling tower having six (6)modular components: two (2) bottom fill sections, two (2) top fillsections, a plenum section, and a fan section. Systems and methodsdisclosed herein may also provide a cooling tower having three (3)modular components: two (2) fill sections, and one (1) combined plenumand fan section. Each of these components may have dimensions that donot exceed certain transportation size limits. Therefore, the componentsmay be transported without special oversize load requirements, therebyreducing transportation costs. Generally, very few states imposesignificant travel restrictions on loads that are ten (10) feet or lessin width. Accordingly, such systems and methods disclosed herein mayprovide a cooling tower that can be assembled with various componentsthat are each ten (10) feet or less in width. In particular, thecontainerized version may be 2.2 meters or less in width. While thesemodular components may require additional trucks for transporting to ajob site—for example, multiple trucks may be needed to carry theseparate components instead of a single oversized truck for carrying anentire cooling tower—the cost savings associated with not having anoversized load (e.g., for not having to pay for certain permitrequirements) may outweigh the added cost of having additional trucks.Furthermore, when using larger capacity towers in larger capacityapplications requiring multiple towers (e.g., cells), fewer towers orcells are required on site. Moreover, such systems and methods mayprovide a method for transporting and assembling cooling towers usingfactory-assembled components in regions that do not allow for thetransportation of oversized loads.

System and methods disclosed herein also provide a cooling tower havingmodular components that can be transported in standard sea containersfor international markets. For example, a standard sea container mayhave a door width of 7′6″ and a door height of 7′5″ and overalldimensions of 40′-by-8′-by-8′6″. Accordingly, such systems and methodsmay provide modular components for a cooling tower that are sized to fitin such a container.

Referring now to FIG. 1, a first exemplary modular heat transfer tower100 is depicted. The modular heat transfer tower 100 may be, forexample, a cooling tower or the like. The modular heat transfer tower100 may comprise six (6) modules including: a first collection basinmodule 110, a plenum module 112, a second collection basin module 114, afirst heat exchange module 120, a fan module 122, and a second heatexchange module 124. The modular heat transfer tower 100 may alsocomprise a first water basin 102 and a second water basin 104. Waterbasins 102, 104 may be examples of the first basin and the second basin,as set forth in the claims.

The first water basin 102 may be disposed in the first collection basinmodule 110, and the second water basin 104 may be disposed in the secondcollection basin module 114. More specifically, the first water basin102 may be disposed at a bottom portion of the first collection basinmodule 110, and the second water basin 104 may be disposed at a bottomportion of the second collection basin module 114. The first collectionbasin module 110 and the second collection basin module 114 may belaterally spaced apart from one another, and thus the first water basin102 and the second water basin 104 may be laterally spaced apart fromone another.

As depicted in FIG. 1, the water basins 102, 104 are separately sealedfrom each other. The water basins 102, 104 may be sealed in a factoryprior to being transported to a job site for final assembly in themodular heat transfer tower 100. Alternatively, the water basins 102,104 may be partially constructed in a factory and sealed at a job site.Furthermore, while the water basins 102, 104 are depicted as separatelysealed units in FIG. 1, one of ordinary skill in the art wouldappreciate that the water basins 102, 104 need not be separately sealedbut can be in fluid communication with one another such that they form acommon basin.

As depicted in FIG. 1, the plenum module 112 is disposed in the spacebetween the first collection basin module 110 and the second collectionbasin module 114. Together, the first collection basin module 110, theplenum module 112, and the second collection basin module 114, may forma first layer—specifically, a bottom layer or base—of the modular heattransfer tower 100.

In a separate layer—specifically, a top layer—the first heat exchangemodule 120, the fan module 122, and the second heat exchange module 124may be disposed. The first heat exchange module 120 may be disposedabove the first collection basin module 110 or, in other words, thefirst heat exchange module 120 may be disposed vertically adjacent tothe first collection basin module 110. And the second heat exchangemodule 124 may be disposed above the second collection basin module 114or, in other words, the second heat exchange module 124 may be disposedvertically adjacent to the second collection basin module 114. The heatexchange modules 120, 124 may be disposed vertically adjacent to thecollection basin modules 110, 114 in a longitudinal direction. Thecollection basin modules 110, 114 and the heat exchange modules 120, 124may have openings along their exterior sides for allowing air fromoutside of the modular heat transfer tower 100 to travel into themodular heat transfer tower 100 or, specifically, to travel into thecollection basin modules 110, 114 and the heat exchange modules 120,124.

The fan module 122 may be disposed vertically adjacent to the plenummodule 112. Both the plenum module 112 and the fan module 112 maycomprise hollow chambers for receiving air travelling through thecollection basin modules 110, 114 and the heat exchange modules 120, 124from outside of the modular heat transfer tower 100. The fan module 122may also include a supporting attachment for holding a fan cylinder anda fan 106. The fan 106 may be an example of an air current generator,such as a fan or impeller. The fan 106 may pull the air that travelsthrough the collection basin modules 110, 114 and the heat exchangemodules 120, 124 from the outside atmosphere into the plenum module 112and the fan module 122 and back out into the atmosphere.

Additionally, the modular heat transfer tower 100 may comprise a firsthot water basin 138 and a second hot water basin 140 (see, e.g., FIGS. 3and 4). The first hot water basin 138 may be disposed in the first heatexchange module 120, and the second hot water basin 140 may be disposedin the second heat exchange module 124. More specifically, the first hotwater basin 138 may be disposed in a top portion of the first heatexchange module 120, and the second hot water basin 140 may be disposedin a top portion of the second heat exchange module 124. Each of thefirst hot water basin 138 and the second hot water basin 140 maycomprise a plurality of openings or apertures 108. The openings may beconfigured to allow a liquid that is placed in the hot water basins 138,140 to travel out of the hot water basins 138, 140 and into lowerregions of the modular heat transfer tower 100 typically vianozzles—specifically, into fill portions or sections disposed in theheat exchange modules 120, 124. Further details regarding the travel ofliquid from the hot water basins 138, 140 and through the modular heattransfer tower 100 is described in reference to FIG. 4, below.

Referring now to FIG. 2, an exploded view of the modular heat transfertower 100 is depicted. This exploded view shows in greater detail eachof the six (6) modular components—the collection basin modules 110, 114;the plenum module 112; the heat exchange modules 120, 124; and the fanmodule 122—of the modular heat transfer tower 100. This exploded viewshows that the first water basin 102 is disposed in the first collectionbasin module 110, and the second water basin 104 is disposed in thesecond collection basin module 114. The exploded view also shows thatthe fan 106 is disposed in the heat exchange modules 120, 124 and thefan module 122.

Referring now to FIG. 3, a top view of the modular heat transfer tower100 is depicted. As depicted in FIG. 3, the heat exchange modules 120,124 and the fan module 122 are disposed adjacent to oneanother—specifically, the fan module 122 is disposed between the firstheat exchange module 120 and the second heat exchange module 124.Further, as shown in FIG. 3, the first hot water basin 138 extends alonga length of the first heat exchange module 120, and the second hot waterbasin 140 extends along a length of the second heat exchange module 124.

FIG. 4 depicts a cross-sectional view of the modular heat transfer tower100 along the line A-A and in the direction of the arrows depicted inFIG. 3. As shown in this cross-sectional view, each of the collectionbasin modules 110, 114 and the heat exchange modules 120, 124 include afill portion. Specifically, the first collection basin module 110includes a first fill portion 130. The second collection basin module114 includes a second fill portion 132. The first heat exchange module120 includes a third fill portion 134. And the second heat exchangemodule 124 includes a fourth fill portion 136. The fill portions 130,134 may form a first heat exchange section, and the fill portions 132,136 may form a second heat exchange section.

While the heat exchange modules 120, 124 are described as containingfill, one of ordinary skill in the art would appreciate that the heatexchange modules 120, 124 may comprise other heat exchange means, suchas, for example, closed circuit coils or tube bundles.

During operation, hot water placed in the hot water basins 138, 140 maytravel through the modular heat transfer tower 100 in the longitudinaldirection towards the cold water basins 102, 104. Specifically, hotwater that is placed in the first hot water basin 138 may travel throughthe openings 108 in the first hot water basin 138 and into the thirdfill portion 134 and then into the first fill portion 130. In otherwords, the first fill portion 130 and the third fill portion 134 form acontinuous path for the hot water which is placed in the first hot waterbasin 138 to travel along and into the first cold water basin 102. Asthe hot water travels along the length of the first fill portion 130 andthe third fill portion 134 or, the first fill section, it is cooled bycooler ambient air that travels horizontally (or substantiallyhorizontally) into the first collection basin module 110 and the firstheat exchange module 120 or, specifically, the first fill portion 130and the third fill portion 134 disposed in the first collection basinmodule 110 and the first heat exchange module 120, respectively, fromoutside of the modular heat transfer tower 100. Thus, when the hot waterreaches the first cold water basin 102, it has been cooled and istherefore received as cold water in the first cold water basin 102. Theambient air, which has been used to cool the hot water, is drawn intothe plenum module 112 and the fan module 122 by the fan 106 and upwardsand out of the modular heat transfer tower 100.

Similarly, hot water placed in the second hot water basin 140 may travelthrough the openings 108 in the second hot water basin 140 and into thefourth fill portion 136 and the second fill portion 132. The hot waterthat is placed in the second hot water basin 140 is separate from thehot water that is placed in the first hot water basin 138. Like thefirst fill portion 130 and the third fill portion 134, the second fillportion 132 and the fourth fill portion 136 form a continuous path forthe hot water which is placed in the second hot water basin 140 totravel along and into the second cold water basin 104. Much in the sameway that the hot water placed in the first water basin 138 is cooled,the water placed in the second hot water basin 140 is cooled usingcooler ambient air which enters the second fill portion 132 and thefourth fill portion 136 from the sides of the second collection basinmodule 114 and the second heat exchange module 124.

The operation of cooling the hot water that is placed in the hot waterbasins 138, 140 that is described in that of a cross-flow cooling tower.Thus, the fill portions 130, 132, 134, 136 may comprise cross-flow fill.

To assemble the modular heat transfer tower 100 depicted in FIG. 1, thebottom layer of modules may be positioned, and then the top layer ofmodules may be positioned on top of the bottom layer of modules. Forexample, the first collection basin module 110 may be positioned, andthe second collection basin module 114 may be positioned laterallyspaced apart from the first collection basin module 110. The plenummodule 112 may be positioned in the space between the first collectionbasin module 110 and the second collection basin module 114. The plenummodule may be positioned prior to the fill modules. The first heatexchange module 120 may be positioned on top of (or vertically adjacentto) the first collection basin module 110, and the second heat exchangemodule 124 may be positioned on top of (or vertically adjacent to) thesecond collection basin module 114. The first heat exchange module 120and the second heat exchange module 124 may be placed such that the fillportions 134, 136 line up with the fill portions 130, 132, respectively,such that the fill portion 130 and the fill portion 134 create acontinuous fill section and the fill portion 132 and the fill portion136 create a continuous fill section. The fan module 122 may bepositioned on top of the plenum module 112 in between the first heatexchange module 120 and the second heat exchange module 124. The fanmodule may be positioned prior to the fill modules.

The modular heat transfer tower 100 depicted in FIG. 1 comprises asingle cell. Nonetheless, one of ordinary skill in the art wouldappreciate that the module heat transfer tower 100 may comprise morethan one cell. Importantly though, as depicted in FIG. 1, each cell ofthe modular heat transfer tower 100 would comprise at least two (2)water basins (e.g., water basins 102, 104), and each cell can be dividedinto six (6) modules.

Each of the six (6) modules of the modular heat transfer tower 100 maybe assembled in a factory and transported to a job site for finalassembly in the modular heat transfer tower 100. In particular, thefirst collection basin module 110 may be assembled in a factoryincluding the first water basin 102, and the second collection basinmodule 114 may be assembled in a factory including the second waterbasin 104. Because both the first water basin 102 and the second waterbasin 104 are assembled into modules at the factory, no water sealingwould need to be done at the job site where the modular heat transfertower 100 is assembled. The fan 106 and the fan cylinder (not labeled)may be assembled at the job site.

Referring now to FIG. 5, a second exemplary modular heat transfer tower200 is depicted. The modular heat transfer tower 200 may comprise six(6) modules including: a first collection basin module 210, a plenummodule 212, a second collection basin module 214, a first heat exchangemodule 220, a fan module 222, and a second heat exchange module 224. Themodular heat transfer tower 200 may also comprise a first water basin202 and a second water basin 204. The modular heat transfer tower 200may also comprise a fan 206 and hot water basins 238, 240 withthrough-holes 208 (depicted in FIG. 6).

The first collection basin module 210 may comprise the first water basin202 and a fill portion 230 (depicted in FIG. 7). Or, stated differently,the first water basin 202 and the fill portion 230 may be disposed inthe first collection basin module 210. The second collection basinmodule 214 may comprise the second water basin 204 and a fill portion232 (depicted in FIG. 7). The first heat exchange module 220 maycomprise a fill portion 234, and the second heat exchange module 224 maycomprise a fill portion 236.

The modular heat transfer tower 200 is similar to the modular heattransfer tower 100 in all respects except that the plenum module 212 andthe fan module 222 are positioned slightly offset in the longitudinaldirection from the collection basin modules 210, 220 and the heatexchange modules 214, 224.

FIG. 7 depicts a cross-sectional view of the modular heat transfer tower200 along the line B-B in the direction depicted in FIG. 6. As shown inFIG. 7, the plenum module 212 and the fan module 222 are slightly raisedin the longitudinal direction as compared to the collection basinmodules 210, 220 and the heat exchange modules 214, 224. Accordingly,the fan 206 may be disposed entirely above the heat exchange modules214, 224 and the fan module 222. Such an elevated placement of the fan206 may create a more efficient flow of air through the modular heattransfer tower 200 as compared to the modular heat transfer tower 100.Moreover, the plenum module 212 may be positioned such that the bottomof the plenum module 212 does not contact a surface on which thecollection basin modules 210, 220 are placed. In other words, the plenummodule 212 may be elevated in relation to the water basins 202, 204(disposed in bottom portions of the collection basin modules 210, 220,respectively). By elevating the plenum module, access under the tower isenhanced and can provide better access to piping.

Turning now to FIG. 8, another exemplary modular heat transfer tower 300is depicted, similar to that described previously in connection withFIG. 1. The modular heat transfer tower 300 may be, for example, acooling tower or the like. The modular heat transfer tower 300 comprisessix (6) modules including: a first collection basin module 310, a plenummodule 312, a second collection basin module 314, a first heat exchangemodule 320, a fan module 322, and a second heat exchange module 324. Themodular heat transfer tower 300 also includes a first water basin 302and a second water basin 304. Water basins 302, 304 may be examples ofthe first basin and the second basin, as set forth in the claims.

The first water basin 302 may be disposed in the first collection basinmodule 310, and the second water basin 304 may be disposed in the secondcollection basin module 314. More specifically, the first water basin302 is disposed at a bottom portion of the first collection basin module310, and the second water basin 304 is disposed at a bottom portion ofthe second collection basin module 314. The first collection basinmodule 310 and the second collection basin module 314 are laterallyspaced apart from one another, and thus the first water basin 302 andthe second water basin 304 are laterally spaced apart from one another.

As depicted in FIG. 8, the water basins 302, 304 are separately sealedfrom each other. The water basins 302, 304 may be sealed in a factoryprior to being transported to a job site for final assembly in themodular heat transfer tower 300. Alternatively, the water basins 302,304 may be partially constructed in a factory and sealed at a job site.Furthermore, while the water basins 302, 304 are illustrated asseparately sealed units in FIG. 8, one of ordinary skill in the artwould appreciate that the water basins 302, 304 need not be separatelysealed but can be in fluid communication with one another such that theyform a common basin.

As depicted in FIG. 8, the plenum module 312 is disposed in the spacebetween the first collection basin module 310 and the second collectionbasin module 314. Together, the first collection basin module 310, theplenum module 312, and the second collection basin module 314, form afirst layer 301—specifically, a bottom layer or base—of the modular heattransfer tower 300.

In a separate layer—specifically, a top layer—the first heat exchangemodule 320, the fan module 322, and the second heat exchange module 324may be disposed. The first heat exchange module 320 may be disposedabove the first collection basin module 310 or, in other words, thefirst heat exchange module 320 may be disposed vertically adjacent tothe first collection basin module 310. And the second heat exchangemodule 324 may be disposed above the second collection basin module 314or, in other words, the second heat exchange module 324 may be disposedvertically adjacent to the second collection basin module 314. The heatexchange modules 320, 324 may be disposed vertically adjacent to thecollection basin modules 310, 314 in a longitudinal direction. Thecollection basin modules 310, 314 and the heat exchange modules 320, 324may have openings along their exterior sides for allowing air fromoutside of the modular heat transfer tower 300 to travel into themodular heat transfer tower 300 or, specifically, to travel into thecollection basin modules 310, 314 and the heat exchange modules 320,324.

The fan module 322 may be disposed vertically adjacent to the plenummodule 312. Both the plenum module 312 and the fan module 322 maycomprise hollow chambers for receiving air travelling through thecollection basin modules 310, 314 and the heat exchange modules 320, 324from outside of the modular heat transfer tower 300. The fan module 322may also include a supporting attachment for holding a fan cylinder anda fan (not pictured). The fan may be an example of an air currentgenerator, such as a fan or impeller. The fan 306 pulls the air thattravels through the collection basin modules 310, 314 and the heatexchange modules 320, 324 from the outside atmosphere into the plenummodule 312 and the fan module 322 and back out into the atmosphere.

Additionally, the modular heat transfer tower 300 may comprise a firsthot water basin 338 and a second hot water basin 340. The first hotwater basin 338 may be disposed in the first heat exchange module 320,and the second hot water basin 340 may be disposed in the second heatexchange module 324. More specifically, the first hot water basin 338may be disposed in a top portion of the first heat exchange module 320,and the second hot water basin 340 may be disposed in a top portion ofthe second heat exchange module 324. Each of the first hot water basin338 and the second hot water basin 340 may comprise a plurality ofopenings or apertures. The openings are configured to allow a liquidthat is placed in the hot water basins 338,340 to travel out of the hotwater basins 338,340 and into lower regions of the modular heat transfertower 300 typically via nozzles—specifically, into fill portions orsections disposed in the heat exchange modules 320, 324.

Turning now to FIGS. 9 and 10, it is standard practice to have coldwater basins without an outlet to be in fluid communication with a coldwater basin having an outlet via a flume. In such designs, the water inthe basin without the outlet must pass through the flume to access theoutlet which is typically accomplished via to gravity. In order forgravity to push water through the flume, the water level in the basinwithout an outlet, must increase in depth. This can typically increasethe operating weight of the tower and/or increase the water level,flooding the bottom of the fill, resulting in a loss in performance.Accordingly, this is to be avoided if possible.

As illustrated in FIGS. 9 and 10, the modular heat exchange tower 300has a basin depressed portion 350 disposed within the heat exchangetower 300. The basin depressed portion serves to provide higher head(water depth) over the water outlet without requiring the respectivebottom modules basins to carry that depth of water over their entireplan area. More specifically, the heat exchange tower 300 includes asuction hood 352 that may extend from the plenum module 312, to theadjacent collection basin modules 310,314. As more clearly illustratedin FIGS. 11 and 12, the hood 352 is positioned or oriented over a outlet354 and extends therefrom to the adjacent collection basin modules310,314. Specifically, the suction hood extends from the basin with anoutlet, i.e., the plenum module 312 outlet, through the flume openinginto the basins without an outlet, i.e., the heat collection basinmodules 310,314 wherein it pulls water directly from the basin with nooutlet to the outlet, thus eliminating potential flume limitations.

As previously discussed, each module contains a depressed floor section.The depressed sections of the outer modules, are connected to thedepressed section of the middle module with a flume. This allows fluidto pass from the outer modules to the middle module, where the fluid ispassed out of the cooling tower. The flume must be fluid tight, and notallow fluid to pass outside of tower. Also as described, a trapezoidalcutout is placed in the depressed sections of the basin sides to allowfluid to pass between basins. The perimeter of the flume cutout isframed with members utilized to seal and connect the adjacent flumes.

In a preferred embodiment of the present invention, the bottom of thecutout may be above or at the same level as the depressed section floor.By extending the cutout down to the same level as the depressed sectionfloor, more fluid is allowed to pass through the flume opening for agiven operating fluid depth. This can result in a lower operating fluiddepth, which in turn reduces the operating weight of the tower.

As illustrated in the figures, in one preferred embodiment the suctionhood 352 is constructed from a series of individual components or partsthat may vary in size and number depending upon the application and theplan of the modular tower. Also as illustrated in FIGS. 9-11, suctionhood 352 has a first inlet end 356 and a second inlet end 358. The firstinlet 356 extends into the basin 302 while the second inlet 358 extendsinto the second basin 304. In one preferred embodiment of the presentinvention, the first and second inlets 356, 358 preferably have atrapezoidal configuration or geometry as illustrated, howeveralternative embodiments of the present invention may have geometriesthat vary, for example, rectangular, polygonal, circular or curvilinear.

As previously described, the suction hood 352 extend from a module withthe outlet, e.g. the plenum module, through the flume opening in thebasin side 380 and into the basin without an outlet, e.g., the basins302 and 304. Accordingly, during operation, the suction hood 352 pullswater directly from the basins with no outlet to the outlet. Moreover,the flow area into the hood may be from the sides, the sides and end, orjust the end as illustrated. The suction hood can extend into as many as4 different basins that do not have an outlet. Also, the area betweenthe suction hood and the sides of the flume allows water to pass betweenthe suction hood and the flume to equalize the water in the basins. Aseparate equalizer is therefore not required.

Turning now to FIGS. 12-14, a flow path connection, generally designated381 that connects adjacent to modules is pictured. As illustrated theflow path connection 381 is trapezoidal in geometry to compliment theflume design. As previously discussed, the flume has primarily twopurposes: (1) To transfer water from the heat exchange basins 302, 304to the outlet 354; and (2) To equalize the liquid levels between thebasins.

As illustrated in FIG. 13, the new flume design and flow opening 380 aretrapezoidal in geometry. Water basin 302 and plenum module 312 areconnected at flow opening 380 via flow connection 381 wherein said flowconnection comprises angles that attach to the basins sides 382 having apair of side walls 384, 386 extending therefrom. Also, each module has aflange 388 to which the connection 381 attaches. Each sidewall 384, 386is sloped at an angle. In one preferred embodiment, the base 382 andopposing sidewalls 384, 386 are a single, contiguous plate 390 whereinthe plate is bent or creased to form the base and respective sides.

To effect a water tight connection, sealer is first applied to themating surfaces of plate 390 of the respective modules including flanges388. During insertion or assembly, the sidewalls 384, 386 of the plate390 are pulled inward. The inflexion or “pulling inward” of thesidewalls 384, 386 is to prevent the smearing of sealer on the sideflanges 388 of the respective modules. As illustrated in FIG. 13, holesin the bottom of the modules are aligned with holes in the plate (bothon the base and respective sidewalls). Next, the bottom or base 382 ispressed into the sealer on the bottom of the modules. Bolts (notpictured) are then installed along the bottom sealingly attaching thebase 382. The sidewalls 384, 386 are then pressed into the sealer wherefasteners are similarly inserted, and when tightened seal theattachments to the sidewalls.

More specifically, as previously described, in one embodimentencompassed by the present invention, preferably a one piece trapezoidalflume is used to connect one basin to the other. Next, sealer is appliedto the members framing the cutouts in the basin sides. The height of thetrapezoidal flume insert is less than the height of the cutout in thebasin side. This allows the flume insert to be raised up above thesealer as it is placed over the members framing the cut out. The flumeinsert is then lowered down into position and fastened to the frame. Asthe fasteners are tightened the sealer compresses and forms a fluidtight seal. The shape of the cutout allows for the flume to be insertedand lowered down onto the sealer. By lowering the insert, the sealerdoes not get wiped away or disturbed, thus providing a superior seal.

As described above, the flume design in accordance with an embodiment ofthe present invention, has sloping or angled sidewalls 384, 386 thatallow the flume section to be set in place, in a manner that compressesthe sealer (or gasket) instead of smearing the sealant and causingpotential leakage. The angle of the sidewalls 384, 386 are fabricated orangled such that they are more upright than the cutout in the basin sideand as described, during assembly or insertion, the bottom is attachedfirst. The sidewalls are then gradually pulled into place, starting fromthe bottom and working upward.

The preferred embodiment trapezoidal shape is not the only shape thatcan accomplish the desired connection and effective seal. For example,the shape could be V-shaped or semicircular. The connection plate endsare again pulled inward prior to insertion to prevent contact of theplate surfaces from smearing the sealer. The bottom of the plate ispositioned and the pressed into the sealer and fastened. Progressivelythe rest of the plate is positioned and fastened until the entire plateis positioned and fastened. In the case of the V-shaped embodiments, thebottom or base may be an apex where the connection plates meet or join.In such embodiments, the apex is pressed into the sealer first, prior tothe sides being pressed into position.

This above-described shape allows for the flow connection 381 to be asingle piece in the water retaining areas verses designs that employmultiple components, and thus, multiple seams below the water levelwhich may lead to leakage. In alternative embodiments the flowconnection 381 may (but is not required to) extend all the way to thefloor, reducing water levels in the basin, and increasing flow rate. Acover may be used to close off the top of the flume.

The many features and advantages of the invention are apparent from thedetailed specification, and, thus, it is intended by the appended claimsto cover all such features and advantages of the invention which fallwithin the true spirit and scope of the invention. Further, sincenumerous modifications and variations will readily occur to thoseskilled in the art, it is not desired to limit the invention to theexact construction and operation illustrated and described, for examplean induced draft heat exchanger has been illustrated but a forced draftdesign can be adapted to gain the same benefits and, accordingly, allsuitable modifications and equivalents may be resorted to that fallwithin the scope of the invention. As noted above, another example isreplacing one or more of the modules containing fill with modules thatmay include closed circuit coils or tube bundles for cooling and/orcondensing fluids. In yet another example one or more modules mayinclude fill and closed circuit coils, tube bundles, or splash bars.

Another construction in the spirit of the scope of this invention is toadd more modules in plan view. For example a tower of approximatelytwice the cooling capacity could be comprised of twice as manycollection basin modules, twice as many heat exchange modules and fourtimes as many plenum and fan modules. More than twice as many plenum andfan modules may desirable to place a larger diameter fan. Furthermore,an odd number of plenum and fan modules may desirable to have a centralmodule that contains the fan mechanical equipment, particularly themotor, gearbox, and fan hub.

Yet another construction is spirit of the scope of this invention is toadd more modules vertically. For example additional modules with heatexchangers could be placed between the collection modules and the heatexchange modules as previously described. Additional modules between theplenum modules and the fan modules can be placed to compliment talleroverall heat exchanger assemblies.

Also, in the spirit of the scope of the invention is a constructionusing fewer modules. For example the plenum module or portions of theplenum module can be incorporated in one or both collection basinmodules. Likewise, the fan module or portions of the fan module can beincorporated in one or both of the heat exchange modules.

Another construction in the spirit of the scope of the invention usingfewer modules may be a one module high tower with two collection basinmodules. The plenum and fan may also reside in those same collectionbasin modules but may also reside in a separate single module. In thiscase, the first heat exchange section and the second heat exchangesections are fully contained in the respective collection basin modules.

What is claimed is:
 1. A modular heat exchange tower that extendsvertically along a longitudinal axis, comprising: a first modulecomprising a first basin disposed therein; a second module that definesa plenum, wherein said second module comprises a outlet; a first flumein fluid communication with said outlet, wherein said flume extends fromsaid second module to said first module, wherein said first flumecomprises: a first linear base wall; a first linear side wall thatextends from said first linear base wall at an angle; and a secondlinear side wall that opposes said first linear side wall that extendsat an angle from said first linear base wall, wherein said first flumefurther comprises a first top linear wall that extends between saidfirst and second linear sidewalls generally parallel to the first linearbase wall; a first heat exchange section; and an air current generator.2. The modular heat exchange tower according to claim 1, furthercomprising a third module having a second basin disposed therein.
 3. Themodular heat exchange tower according to claim 1, wherein said firstflume is trapezoidal in geometry.
 4. The modular heat exchange toweraccording to claim 2, further, comprising: a second flume in fluidcommunication with said outlet, wherein said second flume extends fromsaid third module to said second module, wherein the second flumecomprises: a second linear base wall; a third linear side wall thatextends from said second linear base wall at an angle; and a fourthlinear side wall that opposes said third linear side wall that extendsat an angle from said second linear base wall.
 5. The modular heatexchange tower according to claim 4, wherein said second flume furthercomprises a second top linear wall that extends between said third andfourth linear sidewalls generally parallel to the second linear basewall.
 6. The modular heat exchange tower according to claim 5, whereinsaid second flume is trapezoidal in geometry.
 7. The modular heatexchange tower according to claim 2, wherein said first basin comprisesa first depressed section; said second basin comprises a seconddepressed section and said third module comprises a third depressedsection.
 8. The modular heat exchange tower according to claim 7,wherein said first, second and third depressed sections are in fluidcommunication with one another.
 9. The modular heat exchange toweraccording to claim 2, further comprising a second heat exchange section.10. The modular heat exchange tower according to claim 9, furthercomprising: a fourth module; and a fifth module, wherein the first heatexchange section is disposed in the first module and the fourth module,wherein the second heat exchange section is disposed in the third moduleand the fifth module.
 11. The modular heat exchange tower according toclaim 10, wherein the fourth module is positioned vertically adjacent tothe first module along a first axis parallel to the longitudinal axis,wherein the fifth module is positioned vertically adjacent to the thirdmodule along a second axis parallel to the longitudinal axis.
 12. Themodular heat exchange tower according to claim 11, wherein the firstheat exchange section is disposed in the first module and the fourthmodule is further disposed vertically adjacent to the first basin alongthe first axis parallel to the longitudinal axis, wherein the secondheat exchange section disposed in the third module and the fifth moduleis further disposed vertically adjacent to the third basin along thesecond axis parallel to the longitudinal axis.
 13. The modular heatexchange tower according to claim 12, further comprising a sixth module,wherein the sixth module comprises at least a portion of the air currentgenerator.
 14. The modular heat exchange tower according to claim 13,wherein the sixth module is disposed between the fourth module and thefifth module along an axis perpendicular to the longitudinal axis. 15.The modular heat exchange tower according to claim 14, furthercomprising: a third basin; and a fourth basin, wherein the third basinand the fourth basin are configured to receive separate streams ofliquid, wherein the third basin is disposed vertically adjacent to thefirst heat exchange section along the first axis parallel to thelongitudinal axis such that the stream of water received by the thirdbasin flows into the first heat exchange section and into the firstbasin, wherein the fourth basin is disposed vertically adjacent to thesecond heat exchange section along the second axis parallel to thelongitudinal axis such that the stream of water received by the fourthbasin flows into the second heat exchange section and into the secondbasin.
 16. The modular heat exchange tower according to claim 1, whereinthe first heat exchange section comprises cross-flow fill.
 17. Themodular heat exchange tower according to claim 9, wherein the secondheat exchange section comprises cross-flow fill.
 18. A modular heatexchange tower, comprising: a first fluid basin disposed in a firstmodule; a second fluid basin disposed in a second module; a flume thatextends between said first fluid basin and said second fluid basin,wherein said flume comprises: a linear first base wall; a first linearside wall that extends from said first linear base wall at an angle; anda second linear side wall that opposes said first linear side wall thatextends at an angle from said first linear base wall, wherein said flumefurther comprises a first top linear wall that extends between saidfirst and second linear sidewalls generally parallel to the first linearbase wall.